Insulated interlock deck panel with finish roof system

ABSTRACT

My invention the Insulated Interlock Deck Panel with Finish Roof System is the only one of its kind which combines all of the working processes required to build a new roof system or replace and old one in one single step: decking, insulation, waterproofing and protection finish all in one single panel. 
     My invention is economical, stronger with beautiful appearance, energy saver, more functional than the existing roof systems and environmentally safe. 
     
       
         
               
             
                   
               
                 Comparison Chart 
               
               
               
             
                   
                 Construction Process 
               
                   
                 for Insulated Deck with 
               
                 Actual Roof Construction Process 
                 Finish Roof Interlock Panel 
               
                   
               
                 Installation of Deck (wood or metal) 
                 Not necessary 
               
                 Installation of Base Sheet 
                 Not necessary 
               
                 Installation of Insulation 
                 Not necessary 
               
                 Installation of 3 Ply Roof System 
                 Not necessary 
               
                 Installation of Gravel Roof 
                 Not necessary 
               
                 Installation of EDDN System 
                 Not necessary 
               
                 Installation of Metal Thin System 
                 Not necessary 
               
                 Installation of Clay Barrel Type 
                 Not necessary 
               
                 Installation of Flat Clay Tiles 
                 Not necessary 
               
                 Installation of Clay, Flat or Barrel Tile 
                 Not necessary 
               
                 Installation of waterproof/maintenance cost 
                 Not necessary 
               
                 Protection against termites 
                 No necessary

OBJECTIVES

Provide the consumer an Insulated Interlock Deck Panel with Finish Roof System to be utilized on the roof of buildings/houses.

The Insulated Interlock Deck Panel with Finish Roof System will:

-   -   1) Simplify the roof construction process     -   2) Make the construction of roofs economical     -   3) Speed up the roof construction process     -   4) Increase the savings of energy consumption     -   5) Protect the environment

BACKGROUND

After analyzing all the construction processes of the various roof types (EPDM, Shingles, Modified, Built-Up Roof System, Clay Tiles—Barrel and Flat, Metal Thin Roof System, etc.) in the United States, I noticed that they all have various steps in their construction and finishing processes.

The Insulated Interlock Deck Panel with Finish Roof System is a panel that eliminates all those construction processes and saves on labor and materials. It provides for a stronger and less expensive roof with better guaranteed workmanship, beautiful appearance and greater energy conservation than other roof types.

SUMMARY

This invention substitutes all the other roof construction processes except those of reinforced concrete. It's more economical, faster, stronger, safer and more beautiful than all the other roof types.

The process with The Insulated Interlock Deck Panel with Finish Roof System is very simple and can be done by anyone without previous experience. The following details will explain:

The actual roof measurement plans are used by the manufacturing company to make a plan for installation and manufacturer all the necessary panels. Each panel is specifically marked to facilitate the installation according to the Installation Plan (See Graphic #1).

Once the trusses or rafters (wood or metal) are in place, we start the installation of the panels on the first row “A” at the lowest part of the roof (front edge) (See Graphic #1). The first panel (See Graphic #3A) is installed on the left side screwing it in place as indicated on Graphic #10A. Clean all surfaces with PVC cleaner that will be connected with the second panel (Panel A-2). Put the PVC adhesive on the crevice along the right side of Panel #1A and to the left side of Panel #2 (A-2) and connect Panel #2A with Panel 1A, screwing it in place as indicated on graphic 10A. This is done continuously until the first “Row A” is completed. Return to the left side of the roof (See Graphic #1-Row B Panel 1-B) and repeat the process done on Row “A” continuously until all the panels of the last row have been installed (See Graphic #1 Row “D”. After placing the

“Ridge Cap” (See Graphic #7 page 21 of 28)), screw the ridge cap and the installation of the roof is finished.

The exterior surface of the panels are PVC schedule 90, the insulation (IS095+) is compressed and sealed inside the panels.

The regular size of the panels are 48″ L×24″ W, 48″ L×48″ W, 24″ L×24″ W and 9½ to 10 inches thick but can be manufactured in longer panels. The panels can also be in different colors and the top side can be in different designs, clay tiles, flat or semi-circle barrel types etc.

These panels can be installed in any type of roof with any slope because they are secured in place with screws all around each panel. Graphics #3, 4, 5, 6, 7, 8, 9, 10, 10A, 10B, 11 & 12 have the interlock details for construction.

BRIEF DESCRIPTION OF THE GRAPHICS

Graphic #1. Sections and Details Location Plan (page 14 of 28).

This graphic is only a reference for the location of the other graphics, sections and details. The dimensions that appear are only and example what a roof would be in any house or building.

Graphic #2. Typical Interior Panel and Sections. (page 15 of 28).

In this graphic we have all that is related to a typical panel (plan, sections and legend). The plan indicates the superior part of the panel with all its dimensions. These dimensions may vary. The thickness of the exterior part is indicated at ½″, but can be a minimum thickness of ¼″. The thickness of the exterior parts is determined by the load (live and dead load) which it must support in accordance with specifications of the construction codes. According to where they will be installed, the exterior dimensions. large and wide, may vary. In this example, it indicates a dimension of 48″ wide by 96″ long, but there may be smaller panels of 33″ wide by 27¾″ long for the side edge panels and 27″ wide by 48″ long for panels a) “interior lower edge panel” (see graphic #4, section 4-4, page 18 of 28) and 27″ wide by 27¾″ long “lower edge panel corner detail (see Graphic #3, section 3-3, page 16 of 28).

Section 1-1 is a typical panel and indicates the materials that are used and dimensions. The legend indicates a) PVC for all the exterior parts and b) insulation to fill all the interior spaces.

Section 2-2 is a view of the front of the panel.

Graphic #3. Section 3-3 Side Edge Panel (page 16 of 28).

Shows a typical section of the panel utilized along the side edge of thee roof attached to a concrete tie beam, wooden or metal truss and rafters. These side edge panels shall be attached with screws as indicated on Graphic #10A Panels Typical Attachment. The legend indicated the construction materials, PVC for the exterior walls, the 8″ fascia and interior dividers, and the insulation that fills up the inside of the panel.

Graphic #3A. Lower Edge Panel Corner Detail (page 17 of 28)

This panel is used only on the corners, and measures 48″ Long×24″ wide. It is the first panel to be installed. See Graphic #1 (page 12 of 27). The legend indicates the typical construction as indicated in Graphic #10A.

Graphic #4. Section 4-4 Interior Lower Edge Panel (page 18 of 28).

This panel is used only on the lower edge of the roof. It has a continuous 8″ wide and 1″ thick fascia, after the side edge corner panel (see Graphic #3A side edge corner panel with 8″ fascia) is installed at Row A (see Graphic #1). This interior lower edge panel will be installed along the lower edge, the right side edge panel will be finished with Row A (see Graphic #1, page 14 of 28). The legend indicates the construction materials of the panel PVC for the exterior and interior walls, insulation fill the inside of the panel and the panels shall be attached to the trusses, rafters, concrete or steel beams with screws as indicated in Graphic #10A.

Graphic #5. Section 5-5 Enlarge Interior Interlock Detail (page 19 of 28). This is a typical detail and indicates a typical union between two panels. This union is a “key connection”, the top and right side edge of the panels except “the top edge panels” (Row D on Graphic #1) have an opening of 2″ wide and 1″ deep (female connection) along his entire length. The other two edges (the bottom & left side) have a rectangular piece 2″ wide and 1″ projection (male connection) along the entire length. At the time that we are installing the panels, we apply the adhesive “PVC cement” along the female and male connection to seal watertight the panels. Once the “PVC cement” is dry, pieces 2″×4″ at 4′−0″ cc shall be installed below the panels between trusses or rafters as indicated on this graphic. After the installation of the panels with the adhesive PVC cement, the screws shall be installed. The legend indicates the materials of the panels, exterior walls and interior divisions are PVC and insulation inside.

Graphic #6. Section 6-6 Top Edge Panel with Interlock Detail (page 20 of 28).

This panels are 24″ Wide X 24″ Long and 24″ Wide×96″ Long and shall be installed on the last row at each side of the ridge (see Graphic #1 Sections and Details Location Plan page 14 of 28). The legend indicates the materials. PVC for exterior walls and interior division and inside fill with insulation. After the installation of the ridge cap with the adhesive PVC cement, the screws shall be installed with panels shall be installed with screws as indicated on Graphic #10B page 26 of 28.

Graphic 7. Section 7-7 Ridge Cap Detail (page 21 of 28).

The ridge cap is a solid PVC piece. It shall be manufactured in pieces 8′-0″ long and it is the last piece to be installed with adhesive PVC cement. Its shape is like a fungus with 1½″ thick and 4¼″ long (male connection) and a semi-circular cap of 8¾″ wide along its entire length with a minimum of 3¾″ long closing cap. This semicircular cap shall rest over the 2″ edge panels located at each side of the ridge. At each end except the side pieces, shall have an opening of ½″ wide and 1″ deep (female connection) as indicated on Graphic 7 and 1″ projection (male connecting side to side as indicated on Graphic 7. (page 21 of 28, Sect.″12-12″ ) The attachment screws shall be installed after the adhesive is dry.

Graphic #8. Section 8-8 Interior Panel with Interlock Detail.(page 22 of 28)

This is a typical interior panel with interlock details (See Graphic #1, Sections and Details Location Plan, page 14 of 28. This panel has along the top and right side an opening 2″ wide and 1″ deep (female connection). Along the entire length and along the other two sides (bottom and left side) one rectangular piece 2″ wide and 1″ high (male connection) See Graphic #1 for location of panels. The construction is as the other exterior and interior walls PVC and insulation inside the panel.

Graphic #9. Section 9-9 Typical Interior Interlock Detail (page 23 of 28).

As indicated, the same key connections, male and female (See Graphic #1 page 14 of 28) are along the sides. The legend indicates the materials, PVC exterior and interior walls and interior fill with insulation for attachment. See Graphic #10, panel typical attachment page 24 of 28.

Graphic #10. Panel Typical Attachment. (page 24 of 28)

The panel has the same key connection, male and female (See Graphic #1 page 14 of 28) are along the sides.this little cross+indicates the location of the screws.

Graphic #10A. Side Edge Panels, Corner & Lower Edge Panel Attachment Detail. (page 25 of 28).Dimensions: 51″ long, 48″ wide and 10″ thick and 27¾″ long, 27″ wide and 10″ thick.

Graphic #10B. Top Edge Panel Attachment. (page 26 of 28).

This panel is used only at each side of the ridge of the roof, this little cross+indicates the location of the screws and has a male interlock connection (see top edge panel with interlock detail Graphic #6. page 20 of 28).

Graphic #11. Section “10-10”. Typical corner panel with 8″ Fascia (page 27 of 28). The panel and the fascia are a solid piece with a female key connection. Shall be secured in place with screws as indicates on Graphic 10A page 25 of 28.

Graphic #12. Section “11-11”. Typical edge panel with 8″ Fascia (page 27 of 27) This panel and the fascia are a solid piece with a female cornection. 

1) A=PVC (Polyvinyl Chloride) Panel System insulated with finish roof system 2) B=Insulation ISO95+compressed and sealed inside the panel with a minimum Thickness of five (5) inches. 3) Interlock waterproof details (See Graphics # 2, 4, 5, 6, 7, 8, 9, 11 & 12). 4) All walls and surfaces of the panel are built with “PVC Schedule 90”. 5) All panels are insulated deck with finish roof interlock panels. 6) Key connections to interlock panels. See Graphics #2, 4, 5, 6, 7, 8, 9, 11 & 12 7) Graphic #3 & 3A. This panels are corner & side edge panels with 8″ fascia. 8) Graphic #4. This panel is used only at the lower edge of the roof and has an 8″ fascia. 9) Graphic #5. This key connection is used only between the first row A (See Graphic #1) and the last row at the ridge. 10) Graphic #6. This panel is used only at the sides of the “ridge cap”. 11) Graphic #7. This cap is the last piece to be installed with adhesive and screws. 12) Graphic #8. This panel is used to over the roofs area between the first row (See Graphics #1 and #3) and the last row (See Graphics #1 and #6). 13) Graphic #9. This key connection is used to connect the short side of the panels (4′-0″ wide area). See location plan on Graphic #1. 14) Graphics #10, 10A and 10B indicates the location of the screws to attach the Panels to the Trusses, metal o wooden beams. 15) Graphics # 11 &
 12. have the 8″ fascia as a solid piece with the panel. 